Académique Documents
Professionnel Documents
Culture Documents
INDEX
I. General Information . . . . . . . . . . . . . . . . . . . . . . .1
A. Definitions and Symbols . . . . . . . . . . . . . . . . .1
II. Caution and Safety Procedures . . . . . . . . . . . .1.2
A Electric Shock Precautions . . . . . . . . . . . . . ; . 1
6 Arc Ray Protection . . . . . . . . . . . . . . . . . . . . .1.2
C. Welding Fume Safeguards . . . . . . . . . . . . . . . .2
D. Explosion and Fire Prevention . . . . . . . . . . . . .2
E. Engine Safety . . . . . . . . . . . . . . . . . . . . . . . . . .2
F. Regular Maintenance . . . . . . . . . . . . . . . . . . . .2
Ill. Product Description . . . . . . . . . . . . . . . . . . . . . .2.3
.
A . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3
C Description and Features . . . . . . . . . . . . . . . . .3
IV. Preparation and Operation . . . . . . . . . . . . . . . . 3.6
A . Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.
6. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
C. Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . .3
D. Instrumentation and Controls . . . . . . . . . . . 4.5
E. Initial Start-up Procedures . . . . . . . . . . . . . . .5.6
F. Stop Procedures . . . . . . . . . . . . . . . . . . . . . . . .6
G. DC Generator-Dual Range Welding . . . . . . .6
H. AC Generator Loads . . . . . . . . . . . . . . . . . . . . .6
V. Special Features . . . . . . . . . . . . . . . . . . . . . . . . . .7
A . Automatic Idle Control . . . . . . . . . . . . . . . . . . .7
6. Dual-Power Simultaneous DClAC Power . . . .7
C. Automatic Safety Shutdown Circuit . . . . . . . .7
VI . Troubleshooting Chart . . . . . . . . . . . . . . . . . . . .8.9
.
.
ILLUSTRATIONS
Wiring Diagram of DC Engine Control Circuit . . . . . 9
Wiring Diagram of Generator Side . . . . . . . . . . . . . . . 9
Wiring Diagram of AC Generator Circuit . . . . . . . . . 10
Complete Unit Wiring Diagram . . . . . . . . . . . . . . . . .10
Illustration 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
.
Illustration 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Illustration 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Illustration 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Illustration 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
.
GENERAL INFORMATION
L
ENGINE SAFETY
Special safety precautions must be taken while troubleshooting, maintaining, or operating the engine.
NEVER add fuel near an open flame or when the
engine is running!! The engine must be stopped and
allowed to cool. spill fuel when filling tank. If fuel
is spilled, wipe it up PROMPTLY to prevent it from
igniting on contact with hot engine parts or elecrestart the engine until after all
trical sparks.
fumes have been eliminated. remove the radiator
pressure cap when the engine is hot.
ALWAYS
turn the engine off before troubleshooting and maintenance work unless the maintenance work ABSOLUTELY requires it to be running.
provide adequate ventilation for the engine exhaust gases. Operate ALL internal combustion
engines in open, well-ventilated areas or vent the
engine exhaust fumes outdoors.
REGULAR MAINTENANCE
Only qualified electrical technicians should maintain and service this generator. They should perform
regularly scheduled service checks and repair
defects in cables and the welderlgenerator immediately with factory approved repair parts.
PRODUCT DESCRIPTION
SPECIFICATIONS
The following specifications apply to the WG-270-A.
ENGINE
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . Kubota
.
Model . . . . . . . . . : . . . . . . . . . . .DH-850 B (3 cylinders)
Displacement . . . . . . . . . . . . . . . . . . ..52 CID (855 cc)
Lube Oil Capacity . . . . . .8 quarts of HD diesel grade
Coolant Capacity-50150 mix 5 quarts of Antifreeze
Fuel Consumption . . . . . . . . . . . . . ..0.7 gallonslhour
WELDER
Rated Output. . . . . . . . . . . . . . . . . .9,000 watts (9 KW)
Rated Voltage . . . . . . . . . . . . . . . . . . . ..32.5 volts DC
Rated Current . . . . . . . . . . . . . . . . . . . .,270 amps DC
No Load Voltage. . . . . . . . . . . . . . . . . . . . .85 volts DC
Current Range. . . . . . . . . . . . . . . . . . . .60 to 270 amps
Duty Cycle (see below) . . . . . . . . . . . . . . . . . . . ..50%
Welding Rod Diameter . . . . . . . . . . . . . . .1/16" to 114"
GENERATOR
Rated Output. . . . . . . . . . . . . . . . ..7,000 watts (7 KW)
Rated Voltage . . . . . . . . . . . . . . . . . . . . .120/240volts
Rated Current . . . . . . . . . . . . . . . . . . . .58.4129.2 amps
Phase IP.F. IHertz . . . . . . . . . . . . . . . . . .111.0 160 Hz
DUTY CYCLE
The duty cycle implies a load time of 10 minutes in
percentage. For example, a duty cycle of 5O0/0
represents five minutes of loading (welding) and five
minutes of no-load operation (not welding).
The welder is rated at a 50% duty cycle at
270 amps. However, the duty cycle depends upon
the welding current. Select the appropriate duty cycle from the table below to prevent overload.
Welder Current
Duty Cycle %
unavailable or inconvenient, this compact, selfcontained WlNCO DClAC welderlgenerator will provide your repair, maintenance, and power needs.
Typical applications are welding repair and construction, temporary lighting and power for small
hand tools.
The DC welder current is renulated bv an
automatic electronic current control. The nominal
DC arc voltaae is 32.5 volts DC.
The AC generator voltage is maintained at
& 2'/2 O/O no load to full rated load by an electronic
voltage regulator. No harm to the welderlgenerator
results if it is run with no load connected.
ASSEMBLY
This unit comes completely assembled except for
the optional installation of the handles on the end of
the unit and the door locking tabs. The instruction
procedure for installation of the handles is included
separately in this literature package. The lock tab for
the control panel door must be reversed. This will
cause the tab to project through the slot in the door
for padlock installation. Some models will also have
lock tabs for the side doors. Installation is the same
as on the control panel door. Trailer assembly procedure is detailed in the instruction sheet packed
with the optional trailer kit.
The battery is shipped dry for storage and safety
reasons. When the unit is unpacked, the batteryfluid
will be found in two (2) plastic containers packed
under the side door. Carefully remove the battery
and the fluid containers. Pour the battery fluid into
the battery cells to the indicated level. Install the
cell caps and charge the battery overnight (at a four
to six (4 to 6) amp rate) before using.
SITE SELECTION
Careful site selection and proper installation are
essential to ensure personal safety and to maintain
the welderlgenerator in peak operating condition.
Locate the unit as close to the work station (load) as
possible to minimize the voltage drop in the welder
and generator power cables. However, as a safety
precaution, avoid installing the welderlgenerator
directly under the welding table.
For either permanent or portable installation,
select a location that has adequate ventilation yet is
protected from the elements and free from excessive moisture, humidity, dust or other abrasive
materials. Generally, skid and trailer or vehicle
mounted units are outside and ventilation is adequate provided the unit has clearance around the
housing cooling inlets and outlets. In a confined
area, the units must be provided with adequate,
fresh, cool air for engine combustion and cooling,
and the engine exhaust must be safetly directed
away to a well ventilated area. The discharged hot
air from the engine radiator and generator must be
dissipated to prevent recirculation and engine
overheating. The engine exhaust outlet, unless
located outside, must be plumbed to a safe and well
ventilated area. If external exhaust plumbing is not
used, adequate forced ventilation must be employed
to clear the area of toxic and hazardous fumes.
Both permanent and portable skid, trailer or vehicle mounted units should be placed to allow sufficient service and repair access on all sides of the
set. A stationary unit should be bolted to a flat and
firm foundation such as a concrete slab or a
substantial structural framework. A portable unit
should be set up on an elevated, flat and firm foundation such as a level driveway or parking lot.
11
10
1
LOW
I
HIGH
HIGH COOLANT
TEMPERATURE
LOW OIL
PRESSURE
240v.
30A.
CHARGE
hfj d
GLOW PLUG
RUNNING
TIME METER
MAINLINE
CIRCUIT BREAKER
ACV.
IDLE
CONTROL
240 VOLT
GLOW
PLUG
OFF
PUSH TO
STOP ENGINE
-START
START-UP PROCEDURES
50F or above
D30 or D10W30
Below 50 OF*
D10W30
(For all season use)
*Be sure to use D10W30 in cold weather
.-,
Coolant-Fill the radiator with a clean 50150 mixture of antifreeze. Fill and maintain the overflow
coolant tank at the indicated level. Under normal
conditions, it should not be necessary to open the
radiator cap.
STOP PROCEDURES
Follow the procedure below to stop the engine.
Step l-Discontinue welding operations.
Step 2-Turn off the AC main line circuit breaker
(MLCB).
Step 3-Turn On the idle
switch (if
already on).
Step 4-The engine will begin to idle in approximately 10 seconds. Run the engine at IDLE speed
with no load for about five minutes.
Step 5-Turn the starter key switch to OFF.
Welding
Current
25
50
60 AMP
100 AMP
150 AMP
200 AMP
270 AMP
#4 Ga
#4 Ga
#4 Ga
#3 Ga
#2 Ga
#4 Ga
#3 Ga
#3 Ga
#1 Ga
#1 Ga
pimiml
250
300
#2 Ga
#2 Ga
#I10
#2/0
#310
#2 Ga
#I10
#310
#410
250MCM
#1 Ga
#210
#310
250MCM
300MCM
#3 Ga
#3 Ga
#2 Ga
#I10
#I10
#2 Ga
#1 Ga
#210
#310
#410
AC GENERATOR LOADS
Make sure the engine is running at
full speed whenever welding.
Electrode Diameter
to
to
5/32"
114"
I-[
SPECIAL FEATURES
AUTOMATIC IDLE CONTROL
L
DUAL-POWER SIMULTANEOUS
DClAC POWER
You can use the WlNCO WG-270-A as welder and a
generator at the same time. The WG-270-A supplies
electric power to the AC electrical loads such as
electric lights and tools while the welding continues
unaffected.
When using the AC power at the
same time as welding, be sure to consult the dual power table to ensure that the
engine will not be overloaded.
Example:
Drill nameplate data 120 V AC @ 1.7 A
Compressor Data
240 V AC @ 5.4 A
Calculate the AC Load (watts):
volts x amps = watts
120 volts x 1.7 amps = 204 watts
240 volts x 5.4 amps = 1296 watts
1500 watts total
AC Generator Output
(Total AC Power)
(AC Current @)
240V or 120V'
Watts
29.2A 58.4A
7000 W
60A
25.OA 50.OA
6000 W
130A
18.8A 37.5A
4500 W
160A
12.5A 25.OA
3000 W
200A
6.3A 12.5A
1500 W
230A
Light loads (less than 500 watts)
270A
*240 volt or 120 volt load current. Combinations of
current not to exceed the total AC load power
(watts).
TROUBLESHOOTING TABLE
Symptom
No power generated in
AC generator
Possible Cause
Remedy
Replace
Replace
Replace brush
Polish with sandpaper
Turn in lathe
Replace bearings
Repair and connect
Replace
Replace and connect
Fasten, repair, connect
Symptom
No DC welding
No DC welding possible;
no power
Poor welding; low AC voltage
Possible Cause
Remedy
CL:
OL:
WL:
OPS:
WTS:
SDS:
SB:
CHARGE LAMP
ALARM LAMP FOR LOW O I L PRESSURE
ALARM LAMP FOR HIGH COOLANT TEMPERATURE
LUB. O I L PRESS. SWITCH
WATER TEMP. SWITCH
SLOWDOWN SWITCH
STOP BUTTON
STARTER
IDEL SENSING C . T.
TO
REGULATOR
EMERGENCY
RELAY
UNIT
'
-
DCL
(+)
C-,
T o slowdown
control u n i t
AMPERE REGULATOR
1 IA
'
b
L4 L3
VR
VR
I 1
- MANUAL
LOW
HIGH
RANGE SELECTOR
CURRENT
REGULATOR
COUPLER
4P
I 1 1
1 1
RECEPTACLE
L2 L1
STARTER
BATTERY
CL:
01:
YL:
OPS:
MIS;
CHARGE L L U P
A l P R U LLMP TOR LOU O I L PRfSSURL
P l P R U L L U P 1 0 8 H I G H COOLPNl I E U P E R P I U R t
LUB. 0 1 1 PRESS. s n l l c n
Y l l f R IEMP. S Y I l C H
UNIT
10
EMERGENCY
RELAY
Ref.
Description
01 31380040 Frame
03 31390100 Cover
04 31390110 Cover
05 31130180 Lift Yoke
061 21021020 Eng Foot-L
06r 21071030 Eng Foot-R
07 02220036 Shock ASSY.
08 31390120 Cover
09 91010030 Battery
10 92040020 Terminal
11 22050030 Pad Kit
12 21 130030 Retainer
13 22020150 Bolt
14 31190660 Side Panel
15 31190670 Side Panel
16 1537772401 Tank
17 31081070 Flex Pipe
18 31090280 Gasket
19 31090290 Gasket
20 31070910 Muffler
21 31210330 Access Door
22 31020070 Handle
23 31280150 Handle Stop
24 31180130 Roof
25 31390130 Cover
Part No.
Qty.
Ref.
Description
82376-101
82376-103
82376-104
82376-105
82376-106
82376-156
82376-107
82376-108
82376-109
82376-110
82376-111
82376-112
82376-113
82376-114
82376-115
82376-116
82376-117
82376-118
82376-119
82376-120
82376-121
82376-122
82376-123
82376-124
82376-125
1
1
1
1
1
1
4
1
1
2
1
1
2
1
1
1
1
1
1
1
2
4
4
1
2
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
NI*
NI*
11
Part No.
Qty.
82376-126
82376-127
82376-128
82376-129
82376-130
82376-131
82376-132
82376-133
82376-134
82376-135
82376-136
82376-137
82376-138
82376-139
82376-140
82376-141
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1 ~~~~~ 1 / 1
82376-145
82376-146
Illustration 2
Ref.
Description
03
04s
04R
05
06
07
08
NI*
52190010 IdleSol.
51210470 Diode Kit
51210480 Diode Kit
51500020 Relay, SLR
51740030 AC Reactor
31190010 Side Panel
51270010 MagnetSw.
1547160010 Fuel Stop
Solenoid
Not illustrated.
No.
82376-203
82376-204
82376-214
82376-205
82376-206
82376-207
82376-208
82376-209
Part
Qty.
1
3
3
1
1
1
1
1
cue <L..
I\ilcke
kcLo+= pw&CCC
hndi
Illustration 3
Ref.
11
12
13
14
1 Description
51840020 Inst. Plate
1518160221 Relay
1518160191 Chg lnd.
51110080 Resistor
52020560 Amp. Reg.
61850030 Ckt Bd- Bare
51210260 Diode
51210220 Diode
52140010 Idle Cntrl
51290080 Socket
51280450 Relay5il:ics.;c
52021070 A Volt Reg.
1518164601 Alt Reg.
51740040 DC Reactor
part NO.
82376-301
82376-302
82376-303
82376-304
82376-305
82376-306
82376-307
82376-308
82376-309
82376-310
82376-311
82376-312
82376-313
82376-314
~ t v .I
1
1
1
1
L"'-wb--5
Illustration 4
I Ref. 1 Description
51020550 Panel-Bare
51050440 Voltmeter
51650070 E. Time Mtr
51160050 Charge Lamp
51170160 Bulb
51160040 ,Oil Lamp
51170160 Bulb
51160050 Temp. Lamp
51170160 Bulb
1537763612 Start Sw.
51350370 Range Sel.
51190170 Knob
51100240 Amp. Reg.
51190090 Knob
51140470 Transformer
part NO.
82376-411
82376-412
82376-413
82376-414
82376-415
~ t v .I
Ref.
16
17
18
19
20
21
22
23
24
25
26
27
28a
28b
2 8
29
30
Description
61040289 StadBolt
52030050 Bush.Kit
01090013 Washer
01100040 Spr. Washer
01070013 Nut
01240002 Wing Nut
51150100 Ter. Block
1553165951 G I O W P I U ~
51230060 Stop Button
51420170 Id Ctl SW.
51240670 Circ. Brkr.
51260120 Brkr. Ret.
L5-20 TLR 120V120A
L5-30 TLR 120V130A
~L6-30 TLR 240V130A
5-20 DPR 120V120A
52070030 Resist Unit
Part No.
Qty.
82376-416
82376-417
82376-418
82376-419
82376-420
82376-421
82376-422
82376-423
82376-424
82376-425
82376-426
82376-427
56270-000
56359-000
57324-000
50766-000
82376-430
2
2
12
6
6
2
1
1
1
1
1
1
1
1
1
2
1
Illustration 5
Ref.
Description
11061600
01161519
12331260
01200008
11011820
11201570
01030170
12062230
11140051
11130020
11022000
Coupling
Key
Rotor Kit
Ball Bear.
Yoke
Cover
Set Screw
Stator
Brush Holder
Carb Brush
Bracket
part NO.
82376-551
82376-552
82376-553
82376-554
82376-555
82376-556
82376-557
82376-558
82376-559
82376-560
82376-561
,3:?;
~ t v .1
1
1
1
1
1
1
2
1
2
8
1
4S';;qc
$'i~9